Flame retardancy and synergistic flame retardant mechanisms of acrylonitrile-butadiene-styrene composites based on aluminum hypophosphite

Highly Efficient Flame-Retardant and Enhanced PVA-Based Composite Aerogels through Interpenetrating Cross-Linking Networks

Poly(vinyl alcohol) (P)/alginate (A)/MMT (M) (PAM) composite aerogels was modified through interpenetrating cross-linking of methyltriethoxysilane (Ms) or γ-aminopropyltriethoxysilane (K) and calcium ion (Ca²⁺) as a cross-linking agent, respectively. The compressive moduli of the cross-linked PAM/MsCa and PAM/KCa aerogels greatly increased to 17.4 and 22.1 MPa, approximately 10.5- and 8.2-fold of that of PAM aerogel, respectively. The limited oxygen index (LOI) values for PAM/MsCa and PAM/KCa composite aerogels increased from 27.0% of PAM aerogel to 40.5% and 56.8%. Compared with non-cross-linked PAM aerogel, the peak heat release rate (PHRR) of PAM/MsCa and PAM/KCa composite aerogels dramatically decreased by 34% and 74%, respectively, whereas the PAM/KCa aerogel presented better flame retardancy and lower smoke toxicity than the PAM/MsCa aerogel because of the release of more inert gases and the barrier action of more compact char layer during the combustion. The highly efficient flame-retardant PAM-based composite aerogels with excellent mechanical properties are promising as a sustainable alternative to traditional petroleum-based foams.

A Phosphorous-Based Bi-Functional Flame Retardant Based on Phosphaphenanthrene and Aluminum Hypophosphite for an Epoxy Thermoset

A phosphorous-based bi-functional compound HPDAl was used as a reactive-type flame retardant (FR) in an epoxy thermoset (EP) aiming to improve the flame retardant efficiency of phosphorus-based compounds. HPDAl, consisting of two different P-groups of aluminum phosphinate (AHP) and phosphophenanthrene (DOPO) with different phosphorous chemical environments and thus exerting different FR actions, exhibited an intramolecular P-P groups synergy and possessed superior flame-retardant efficiency compared with DOPO or AHP alone or the physical combination of DOPO/AHP in EP. Adding 2 wt.% HPDAl made EP composites acquire a LOI value of 32.3%, pass a UL94 V-0 rating with a blowing-out effect, and exhibit a decrease in the heat/smoke release. The flame retardant modes of action of HPDAl were confirmed by the experiments of the scanning electron microscope (SEM), X-ray photoelectron spectroscopy (XPS), and thermogravimetry–Fourier transform infrared spectroscopy–gas chromatograph/mass spectrometer (TG-FTIR-GC/MS). The results indicate that the phosphorous-based FRs show different influences on the flame retardancy of composites, mainly depending on their chemical structures. HPDAl had a flame inhibition effect in the gas phase and a charring effect in the condensed phase, with a well-balanced distribution of P content in the gas/condensed phase. Furthermore, the addition of HPDAl hardly impaired the mechanical properties of the matrix due to the link by chemical bonds between them.

Phytic Acid-Iron/Laponite Coatings for Enhanced Flame Retardancy, Antidripping and Mechanical Properties of Flexible Polyurethane Foam

The use of flexible polyurethane foam (FPUF) is severely limited due to its flammability and dripping, which can easily cause major fire hazards. Therefore, choosing an appropriate flame retardant to solve this problem is an urgent need. A coating was prepared on the FPUF surface by dipping with phytic acid (PA), Fe2(SO4)3·xH2O, and laponite (LAP). The influence of PA-Fe/LAP coating on FPUF flame-retardant performance was explored by thermal stability, flame retardancy, combustion behavior, and smoke density analysis. FPUF/PA-Fe/LAP has a good performance in the small fire test, which can pass the UL-94 V-0 rating and the limiting oxygen index reaches 24.5%. Meanwhile, the peak heat release rate values and maximum smoke density of FPUF/PA-Fe/LAP are reduced by 38.7% and 38.5% compared with those of neat FPUF. After applying PA-Fe/LAP coating, the value of fire growth rate index decreases from 10.5 kW/(m2·s) to 5.1 kW/(m2·s), dramatically reducing the fire risk. Encouragingly, the effect of PA-Fe/LAP coating on cyclic compression and permanent deformation is small, which is close to that of neat FPUF. This work provides an effective strategy for making a flame-retardant FPUF with antidripping and keeping mechanical properties.

Effect of tris(1-chloro-2-propyl)phosphate in combination with aluminum hypophosphite and melamine polyphosphate on flame retardancy and thermal decomposition of rigid polyurethane foams

RPUF with tris(1-chloro-2-propyl)phosphate (TCPP), melamine polyphosphate (MPP) and aluminum hypophosphite (AHP) alone, as well as their binary and ternary blends, were prepared via a one-step process. The effect of TCPP in combination with AHP and MPP on flame retardancy and thermal decomposition in the RPUF has been investigated. The results show that adding TCPP, MPP and AHP into RPUF simultaneously can significantly ensure the uniform cell structure, enhance the compressive strength, thermal stability and fire resistance of RPUF, decrease the thermal conductivity, the release of toxic HCN at high temperature. TGA results indicate that partial substitution of TCPP with MPP and AHP could improve the char residue. When the content of TCPP is 10 wt%, the optimal ratio of MPP and DPER was 1/2, the TCPP10/MPP3.3/AHP6.7/RPUF sample reached a V1 rating in vertical UL-94 test with a limiting oxygen index of 27.4%. The compressive strength and specific compressive strength (compressive strength/density) for TCPP10/MPP3.3/AHP6.7/RPUF sample increased about 82.6% and 44.3% compared to that of pure RPUF, respectively. The cone calorimeter test results showed that adding EG, MPP and AHP into RPUF simultaneously can significantly decrease the heat release rate (HRR), total heat release (THR) and smoke emission behavior of RPUF sample. Based on these facts, a potential flame-retardant mechanism was proposed.

Mitigation the release of toxic PH3 and the fire hazard of PA6/AHP composite by MOFs

Aluminum hypophosphite (AHP) is a high-efficiency phosphorus-based flame retardant with high P content, which is widely used in Polyamide 6 (PA6). However, AHP releases phosphine gas (PH₃) at high temperatures, which is highly toxic to human's health and environment. Metal-organic frameworks (MOFs) have porous structure exhibiting high performance in gas adsorption. Therefore, mesoporous iron (III) carboxylate [MIL-100 (Fe)] was synthesized in this work and employed to study the adsorption capacity of toxic PH₃ in PA6/AHP composite during processing. AHP was combined with melamine cyanurate (MCA) and MIL-100 (Fe) followed by blending with PA6 to prepare PA6 composites (PA6/MA and PA6/MAF). PA6/MAF with the weight ratio of 5:5 performed well in inhibiting the release of PH₃ during the processing of composite as well as the accelerated thermal experiment devised by our group. Besides, PA6/MAF (5:5) showed relatively low fire hazard reflected by the reduction of the peak of heat release rate of PA6 composite from 962 to 260 kW/m² compared with that of pure PA6 in the cone calorimeter test, and MIL-100 (Fe) along with MCA also presented synergistic effect in suppressing the emission of carbon monoxide. The subtle selection of MOFs herein has the potential to be used as a promising synergist for hazardous gases released from polymer composites to improve the occupational and fire safety in the society.

The Synergistic Effect of Ionic Liquid-Modified Expandable Graphite and Intumescent Flame-Retardant on Flame-Retardant Rigid Polyurethane Foams

In this study, a nitrogen–phosphorus intumescent flame-retardant 3-(N-diphenyl phosphate) amino propyl triethoxy silane (DPES), the ionic liquid (IL) of 1-butyl-3-methyl-imidazole phosphate, and a phosphorous-containing ionic liquid-modified expandable graphite (IL-EG), were synthesized, and their molecular structures were characterized. The flame-retardant rigid polyurethane foams (RPUFs) were compounded with synergistic flame-retardant IL-EG/DPES to study the effects of the combination IL-EG and DPES on the pore structure, mechanical properties, thermal decomposition behavior and thermal decomposition mechanism of RPUF. The results showed that IL-EG/DPES had good thermal stability, and an excellent expansibility and char yield. The flame-retardant RPUF, modified with IL-EG and DPES at the ratio of 1:1, had a relatively uniform pore size, the highest compressive strength, and an excellent flame-retardant performance due to the form interwoven hydrogen bonds between IL-EG and DPES, as well as the new synergistic flame-retardant coating on the RPUF surface to restrict the transfer of gas or heat into the PU matrix.

Study on flame retardancy and smoke suppression of PET by the synergy between Fe2O3 and new phosphorus-containing silicone flame retardant

To reduce the environmental hazard from the flame retardant, a halogen-free phosphorus-containing silicone flame-retardant poly N, N dimethylene phosphate aminopropyl siloxane (PDPSI) was prepared following the Mannich reaction. Then, PDPSI and ferric oxide (Fe2O3) were used for the preparation of synergistic flame-retardant polyethylene terephthalate (PET). The flame-retardant test results revealed that at 2% PDPSI/Fe2O3 content and 1:2 mass ratio of PDPSI to Fe2O3, the limit oxygen index value of the PDPSI/Fe2O3/PET composite material was 27.9%, reaching the flame-retardant level and passing the V-0 rating in the UL-94 test. In addition, the PDPSI/Fe2O3/PET composites had a char residue content of 17.5% at 700°C, an increase of 30.6% compared to that of the pristine PET. In the cone calorimeter test, the addition of PDPSI/Fe2O3 significantly reduced the peak heat release rate (PHRR), total heat release (THR) rate, and total smoke production (TSP) value of the resulting PET composites. PHRR and THR decreased by 66.05% and 14.3%, respectively. The TSP value decreased from 14.4 m2 to 8.1 m2, a decrease of 43.8%. The scanning electron microscopy images and Fourier-transform infrared spectra of the char residue showed a significant synergy between Fe2O3 and PDPSI, changing the structure of the carbon layer in continuous and dense form, thus the flame retardancy and smoke suppression of the PET composites improved. In addition, the tensile strength of the PET composite was 42.11 MPa, which was only 1.84% less than that of the pristine PET.

Fire Properties of Acrylonitrile Butadiene Styrene Enhanced with Organic Montmorillonite and Exolit Fire Retardant

In this paper an experimental investigation on fire retardancy of a new polymer nanocomposite derived from organic montmorillonite and exolit fire retardant in an acrylonitrile- butadiene-styrene copolymer by analyzing the flammability and fire behavior is described. The samples were prepared by melting and mixing nanocomposites and fire retardant in different concentrations in an acrylonitrile-butadiene-styrene base polymer. It was found that using only one component (organic montmorillonite or fire retardant) the burning stops in 10 s on the sample. Confirmation of synergy in flammability by combining both montmorillonite and flame retardants was noticed and is discussed regarding the flame-retardant mechanisms assessed by means of the Limiting oxygen index (LOI), UL 94, and cone-calorimeter methods. The acrylonitrile- butadiene-styrene preparation with 15–20 wt% fire retardant and 1–2 wt% organic montmorillonite reached a UL-94 V-0 classification, contrasting with the pure acrylonitrile- butadiene-styrene and the acrylonitrile-butadiene-styrene with 15 wt% fire retardant and acrylonitrile-butadiene-styrene with 1–2 wt% organic montmorillonite formulations, which completely burned. Finally, the samples showed a very good synergy going to a higher reduction of the peak heat release rate and to a minimum mass reduction, as obtained from cone calorimeter tests.

Flame Retardancy and Toughness of Poly(Lactic Acid)/GNR/SiAHP Composites

A novel flame-retardant and toughened bio-based poly(lactic acid) (PLA)/glycidyl methacrylate-grafted natural rubber (GNR) composite was fabricated by sequentially dynamical vulcanizing and reactive melt-blending. The surface modification of aluminum hypophosphite (AHP) enhanced the interfacial compatibility between the modified aluminum hypophosphite by silane (SiAHP) and PLA/GNR matrix and the charring ability of the PLA/GNR/SiAHP composites to a certain extent, and the toughness and flame retardancy of the PLA/GNR/SiAHP composites were slightly higher than those of PLA/GNR/AHP composites, respectively. The notched impact strength and elongation of the PLA composite with 20 wt. %GNR and 18 wt.% SiAHP were 13.1 kJ/m2 and 72%, approximately 385% and 17 fold higher than those of PLA, respectively, and its limiting oxygen index increased to 26.5% and a UL-94 V-0 rating was achieved. Notedly, the very serious melt-dripping characteristics of PLA during combustion was completely suppressed. The peak heat release rate and total heat release values of the PLA/GNR/SiAHP composites dramatically reduced, and the char yield obviously increased with an increasing SiAHP content in the cone calorimeter test. The good flame retardancy of the PLA/GNR/SiAHP composites was suggested to be the result of a synergistic effect involving gaseous and condensed phase flame-retardant mechanisms. The high-performance flame-retardant PLA/GNR/SiAHP composites have great potential application as replacements for petroleum-based polymers in the automotive interior and building fields.

Effect of Zinc Borate on Enhancing Flame Retardancy of Electron Beam Irradiated Alumina Trihydrate (ATH)/Acrylonitrile Butadiene Styrene (ABS) Composites

The purpose of this research was to investigate the effects of zinc borate loading level and electron beam irradiation dosages on flame retardancy and physico-mechanical properties of ATH-ABS blends. The increasing of irradiation dosage has gradually induced the gel content of all ATH-ABS blends by forming crosslinked networks. The addition of ATH and zinc borate has significantly increased the crystallinity of ABS blends as evident by the elimination of the hump on XRD curves. However, the application of lower electron beam irradiation dosages (≤150 kGy) has slightly decreased the crystallinity of 0 phr and 20 phr zinc borate added samples. The increasing zinc borate loading level from 5 phr to 20 phr has gradually increased the flame retardancy of non-irradiated samples by inducing char formation. Besides, the increasing of irradiation dosage has significantly improved the flame retardancy of all samples. The addition of zinc borate up to 15 phr has effectively increased the tensile strength of all ATH-ABS blends by enhancing the interfacial adhesion between the ATH particles and ABS matrix. The increment of irradiation dosages up to 250 kGy has gradually increased the tensile strength by introducing the formation of crosslinking networks in ABS matrix.

Release and Transformation of BTBPE During the Thermal Treatment of Flame Retardant ABS Plastics

Thermal scenarios inevitably occur during the lifecycle of engineering plastics laden with brominated flame retardants (BFRs). However, little information on the fate of embedded BFRs during the thermal processes is available. In this study, we measured the release and transformation of a typical BFR, 1,2-bis(2,4,6-tribromophenoxy)ethane (BTBPE), during the thermal treatment of acrylonitrile butadiene styrene (ABS) plastics. The possible thermal scenarios were simulated by varying the heating temperature and atmosphere. The maximum release rate of BTBPE was observed at 350 °C. A release kinetic model was developed to explore the mechanism of BTBPE release while heating ABS. Material-phase diffusion was found to be the rate-determining step during release. According to the developed release model, it was estimated that 0.04-0.17% of embedded BTBPE could be released to air during the industrial processing of ABS plastics. When the heating temperature was ≥350 °C, approximately 15-56% of embedded BTBPE decomposed to bromophenols (BPs) and 1,3,5-tribromo-2-(vinyloxy) benzene (TBVOB), and the decomposition followed a first-order kinetics at 350 °C. Polybrominated dibenzo- p-dioxins and dibenzofurans (PBDD/Fs) were also significantly formed at ≥350 °C from BPs and TBVOB via a precursor mechanism. A higher temperature (≥450 °C) was favorable for the formation of PBDFs.

Combination effect of MoS2 with aluminum hypophosphite in flame retardant ethylene-vinyl acetate composites

A series of flame retardant ethylene-vinyl acetate (EVA) composites, with different aluminum hypophosphite (AHP), melamine cyanurate (MCA) and MoS₂ content, has been prepared.

Surface microencapsulation modification of aluminum hypophosphite and improved flame retardancy and mechanical properties of flame-retardant acrylonitrile–butadiene–styrene composites

Silicone-microencapsulated aluminum hypophosphite (SiAHP) improved effectively the flame retardancy and significantly enhanced the notched impact strength of ABS/SiAHP composites.

A novel EVA composite with simultaneous flame retardation and ceramifiable capacity

Ethylene-vinyl acetate (EVA) filled with glass dust (GD), glass fiber (GF), OMMT, and melamine cyanurate (MCA) was developed as a ceramifiable flame-retardant polymer composite for cables and insulated wires.